HP 403349-003 User Manual

HP Modular Cooling System Maintenance and Service Guide

Part Number 403349-003
October 2008 (Third Edition)

© Copyright 2006, 2008 Hewlett-Packard Development Company, L.P.
The information contained herein is subject to change without notice. The only warranties for HP products and services are set forth in the express

warranty statements accompanying such products and services. Nothing herein should be construed as constituting an additional warranty. HP
shall not be liable for technical or editorial errors or omissions contained herein.

Intended audience

This guide is for an experienced service technician. HP assumes you are qualified in the servicing of
computer equipment and trained in recognizing hazards in products with hazardous energy levels and
are familiar with weight and stability precautions for rack installations.

Contents

Customer self repair...................................................................................................................... 6

Parts only warranty service ......................................................................................................................... 6

Illustrated parts catalog ............................................................................................................... 17

Replaceable spare parts........................................................................................................................... 17

Flow meter repair.................................................................................................................................... 20

Removal and replacement procedures........................................................................................... 22

Removal and replacement procedure overview ........................................................................................... 22

Viewing the spare replacement video ........................................................................................................ 22

Customer self repair required tools ............................................................................................................22

Safety considerations............................................................................................................................... 24

Rack warnings and cautions ........................................................................................................... 24

Preparation procedures............................................................................................................................ 24

Powering down the MCS unit.......................................................................................................... 24

Shutting off the water ..................................................................................................................... 25

AC transfer switch ................................................................................................................................... 26

Removing the AC transfer switch ..................................................................................................... 26

Replacing the AC transfer switch ..................................................................................................... 28

Air bleeder valve..................................................................................................................................... 31

Removing the air bleeder valve ....................................................................................................... 31

Replacing the air bleeder valve ....................................................................................................... 32

Air deflector plate ................................................................................................................................... 33

Removing the air deflector plate ......................................................................................................33

Replacing the air deflector plate ...................................................................................................... 34

Air sealing plate...................................................................................................................................... 34

Removing the air sealing plate ........................................................................................................35

Replacing the air sealing plate ........................................................................................................ 36

Automatic door release ............................................................................................................................ 38

Removing the front automatic door release........................................................................................ 38

Replacing the front automatic door release .......................................................................................39

Removing the rear automatic door release ........................................................................................41

Replacing the rear automatic door release........................................................................................ 42

Bottom fan unit........................................................................................................................................ 44

Removing the bottom fan unit .......................................................................................................... 44

Replacing the bottom fan unit.......................................................................................................... 45

Condensation pump and sensors............................................................................................................... 47

Removing the condensation pump and sensors..................................................................................47

Replacing the condensation pump and sensors.................................................................................. 49

Fan unit ................................................................................................................................................. 50

Removing the fan unit..................................................................................................................... 51

Replacing the fan unit .................................................................................................................... 52

Flow meter sensor ................................................................................................................................... 54

Removing the flow meter paddle-wheel sensor................................................................................... 54

Replacing the flow meter paddle-wheel sensor................................................................................... 57

Heat exchanger unit (HEX) with coupler ..................................................................................................... 59

Removing the heat exchanger unit with couplers................................................................................ 59

Contents 3

Replacing the heat exchanger unit with couplers................................................................................ 63

Heat exchanger unit (HEX) with ball valve ..................................................................................................67

Removing the heat exchanger unit with ball valves............................................................................. 68

Replacing the heat exchanger unit with ball valves............................................................................. 72

HEX coupling.......................................................................................................................................... 77

Removing the HEX coupling ............................................................................................................ 78

Replacing the HEX coupling............................................................................................................ 80

Magnetic solenoid valve .......................................................................................................................... 82

Removing the magnetic solenoid valve ............................................................................................. 82

Replacing the magnetic solenoid valve ............................................................................................. 84

Management module............................................................................................................................... 85

Removing the management module..................................................................................................85

Replacing the management module .................................................................................................86

Operator display..................................................................................................................................... 88

Removing the operator display........................................................................................................88

Replacing the operator display........................................................................................................ 91

Power inlet box....................................................................................................................................... 93

Relocating the power inlet box ........................................................................................................ 93

Relocating the power inlet box back into position ..............................................................................95

Water group controller ............................................................................................................................ 97

Removing the water group controller................................................................................................ 97

Replacing the water group controller.............................................................................................. 100

Water inlet coupling.............................................................................................................................. 102

Removing the water inlet coupling ................................................................................................. 102

Replacing the water inlet coupling ................................................................................................. 105

Water temperature sensor ...................................................................................................................... 107

Removing the water temperature sensor.......................................................................................... 107

Replacing the water temperature sensor ......................................................................................... 109

Operation checklist................................................................................................................................ 111

Restoring power to the MCS unit ...................................................................................................111

Restoring water flow .................................................................................................................... 112

Technician repair removal and replacement procedures................................................................ 113

Miscellaneous hardware kit overview....................................................................................................... 113

Technician repair required tools .................................................................................................... 114

Flow meter ...........................................................................................................................................114

Removing the flow meter .............................................................................................................. 114

Replacing the flow meter .............................................................................................................. 117

Magnetic valve ..................................................................................................................................... 118

Removing the magnetic valve diaphragm and spring ....................................................................... 118

Replacing the magnetic valve diaphragm and spring ....................................................................... 120

Upgrading procedures .............................................................................................................. 123

Viewing the upgrade procedures video.................................................................................................... 123

Upgrading the HEX coupler.................................................................................................................... 123

Removing the HEX coupler............................................................................................................ 123

Replacing the HEX coupler............................................................................................................ 128

Upgrading the HEX hose coupler............................................................................................................. 132

Removing the HEX hose coupler ....................................................................................................132

Replacing the HEX hose coupler .................................................................................................... 132

Maintenance............................................................................................................................ 139

Maintenance and service .......................................................................................................................139

Air and water heat exchanger maintenance.................................................................................... 139

Contents 4

Water quality.............................................................................................................................. 139

Condensation management ..........................................................................................................139

Frost damage.............................................................................................................................. 139

Diagnostic tools .................................................................................................................................... 140

Troubleshooting........................................................................................................................ 141

HP Modular Cooling System troubleshooting............................................................................................. 141

Specifications........................................................................................................................... 142

MCS specifications................................................................................................................................ 142

Thermal and air flow performance.................................................................................................143

Environmental specifications ......................................................................................................... 143

HP 10642 G2 Rack specifications........................................................................................................... 143

Acronyms and abbreviations...................................................................................................... 144

Index....................................................................................................................................... 145

Contents 5

Customer self repair

HP products are designed with many Customer Self Repair (CSR) parts to minimize repair time and allow
for greater flexibility in performing defective parts replacement. If during the diagnosis period HP (or HP
service providers or service partners) identifies that the repair can be accomplished by the use of a CSR
part, HP will ship that part directly to you for replacement. There are two categories of CSR parts:

• Mandatory—Parts for which customer self repair is mandatory. If you request HP to replace these

parts, you will be charged for the travel and labor costs of this service.

• Optional—Parts for which customer self repair is optional. These parts are also designed for

customer self repair. If, however, you require that HP replace them for you, there may or may not be
additional charges, depending on the type of warranty service designated for your product.

NOTE: Some HP parts are not designed for customer self repair. In order to satisfy the customer
warranty, HP requires that an authorized service provider replace the part. These parts are identified as
"No" in the Illustrated Parts Catalog.

Based on availability and where geography permits, CSR parts will be shipped for next business day
delivery. Same day or four-hour delivery may be offered at an additional charge where geography
permits. If assistance is required, you can call the HP Technical Support Center and a technician will help
you over the telephone. HP specifies in the materials shipped with a replacement CSR part whether a
defective part must be returned to HP. In cases where it is required to return the defective part to HP, you
must ship the defective part back to HP within a defined period of time, normally five (5) business days.
The defective part must be returned with the associated documentation in the provided shipping material.
Failure to return the defective part may result in HP billing you for the replacement. With a customer self
repair, HP will pay all shipping and part return costs and determine the courier/carrier to be used.

For more information about HP's Customer Self Repair program, contact your local service provider. For
the North American program, refer to the HP website (http://www.hp.com/go/selfrepair

Parts only warranty service

Your HP Limited Warranty may include a parts only warranty service. Under the terms of parts only
warranty service, HP will provide replacement parts free of charge.

For parts only warranty service, CSR part replacement is mandatory. If you request HP to replace these
parts, you will be charged for the travel and labor costs of this service.

).

Réparation par le client (CSR)

Les produits HP comportent de nombreuses pièces CSR (Customer Self Repair = réparation par le client)
afin de minimiser les délais de réparation et faciliter le remplacement des pièces défectueuses. Si pendant
la période de diagnostic, HP (ou ses partenaires ou mainteneurs agréés) détermine que la réparation peut
être effectuée à l'aide d'une pièce CSR, HP vous l'envoie directement. Il existe deux catégories de pièces
CSR:

Customer self repair 6

• Obligatoire - Pièces pour lesquelles la réparation par le client est obligatoire. Si vous demandez à

HP de remplacer ces pièces, les coûts de déplacement et main d'œuvre du service vous seront
facturés.

• Facultatif - Pièces pour lesquelles la réparation par le client est facultative. Ces pièces sont

également conçues pour permettre au client d'effectuer lui-même la réparation. Toutefois, si vous
demandez à HP de remplacer ces pièces, l'intervention peut ou non vous être facturée, selon le type
de garantie applicable à votre produit.

REMARQUE: Certaines pièces HP ne sont pas conçues pour permettre au client d'effectuer lui-même la
réparation. Pour que la garantie puisse s'appliquer, HP exige que le remplacement de la pièce soit
effectué par un Mainteneur Agréé. Ces pièces sont identifiées par la mention "Non" dans le Catalogue
illustré.

Les pièces CSR sont livrées le jour ouvré suivant, dans la limite des stocks disponibles et selon votre
situation géographique. Si votre situation géographique le permet et que vous demandez une livraison le
jour même ou dans les 4 heures, celle-ci vous sera facturée. Pour bénéficier d'une assistance
téléphonique, appelez le Centre d'assistance technique HP. Dans les documents envoyés avec la pièce de
rechange CSR, HP précise s'il est nécessaire de lui retourner la pièce défectueuse. Si c'est le cas, vous
devez le faire dans le délai indiqué, généralement cinq (5) jours ouvrés. La pièce et sa documentation
doivent être retournées dans l'emballage fourni. Si vous ne retournez pas la pièce défectueuse, HP se
réserve le droit de vous facturer les coûts de remplacement. Dans le cas d'une pièce CSR, HP supporte
l'ensemble des frais d'expédition et de retour, et détermine la société de courses ou le transporteur à
utiliser.

Pour plus d'informations sur le programme CSR de HP, contactez votre Mainteneur Agrée local. Pour plus
d'informations sur ce programme en Amérique du Nord, consultez le site Web HP
(http://www.hp.com/go/selfrepair

).

Service de garantie "pièces seules"

Votre garantie limitée HP peut inclure un service de garantie "pièces seules". Dans ce cas, les pièces de
rechange fournies par HP ne sont pas facturées.

Dans le cadre de ce service, la réparation des pièces CSR par le client est obligatoire. Si vous demandez
à HP de remplacer ces pièces, les coûts de déplacement et main d'œuvre du service vous seront facturés.

Riparazione da parte del cliente

Per abbreviare i tempi di riparazione e garantire una maggiore flessibilità nella sostituzione di parti
difettose, i prodotti HP sono realizzati con numerosi componenti che possono essere riparati direttamente
dal cliente (CSR, Customer Self Repair). Se in fase di diagnostica HP (o un centro di servizi o di
assistenza HP) identifica il guasto come riparabile mediante un ricambio CSR, HP lo spedirà direttamente
al cliente per la sostituzione. Vi sono due categorie di parti CSR:

• Obbligatorie – Parti che devono essere necessariamente riparate dal cliente. Se il cliente ne affida

la riparazione ad HP, deve sostenere le spese di spedizione e di manodopera per il servizio.

• Opzionali – Parti la cui riparazione da parte del cliente è facoltativa. Si tratta comunque di

componenti progettati per questo scopo. Se tuttavia il cliente ne richiede la sostituzione ad HP,
potrebbe dover sostenere spese addizionali a seconda del tipo di garanzia previsto per il prodotto.

Customer self repair 7

NOTA: alcuni componenti HP non sono progettati per la riparazione da parte del cliente. Per rispettare
la garanzia, HP richiede che queste parti siano sostituite da un centro di assistenza autorizzato. Tali parti
sono identificate da un "No" nel Catalogo illustrato dei componenti.

In base alla disponibilità e alla località geografica, le parti CSR vengono spedite con consegna entro il
giorno lavorativo seguente. La consegna nel giorno stesso o entro quattro ore è offerta con un
supplemento di costo solo in alcune zone. In caso di necessità si può richiedere l'assistenza telefonica di
un addetto del centro di supporto tecnico HP. Nel materiale fornito con una parte di ricambio CSR, HP
specifica se il cliente deve restituire dei componenti. Qualora sia richiesta la resa ad HP del componente
difettoso, lo si deve spedire ad HP entro un determinato periodo di tempo, generalmente cinque (5) giorni
lavorativi. Il componente difettoso deve essere restituito con la documentazione associata nell'imballo di
spedizione fornito. La mancata restituzione del componente può comportare la fatturazione del ricambio
da parte di HP. Nel caso di riparazione da parte del cliente, HP sostiene tutte le spese di spedizione e
resa e sceglie il corriere/vettore da utilizzare.

Per ulteriori informazioni sul programma CSR di HP contattare il centro di assistenza di zona. Per il
programma in Nord America fare riferimento al sito Web HP (http://www.hp.com/go/selfrepair

Servizio di garanzia per i soli componenti

La garanzia limitata HP può includere un servizio di garanzia per i soli componenti. Nei termini di
garanzia del servizio per i soli componenti, HP fornirà gratuitamente le parti di ricambio.

).

Per il servizio di garanzia per i soli componenti è obbligatoria la formula CSR che prevede la riparazione
da parte del cliente. Se il cliente invece richiede la sostituzione ad HP, dovrà sostenere le spese di
spedizione e di manodopera per il servizio.

Customer Self Repair

HP Produkte enthalten viele CSR-Teile (Customer Self Repair), um Reparaturzeiten zu minimieren und
höhere Flexibilität beim Austausch defekter Bauteile zu ermöglichen. Wenn HP (oder ein HP
Servicepartner) bei der Diagnose feststellt, dass das Produkt mithilfe eines CSR-Teils repariert werden
kann, sendet Ihnen HP dieses Bauteil zum Austausch direkt zu. CSR-Teile werden in zwei Kategorien
unterteilt:

• Zwingend – Teile, für die das Customer Self Repair-Verfahren zwingend vorgegeben ist. Wenn Sie

den Austausch dieser Teile von HP vornehmen lassen, werden Ihnen die Anfahrt- und Arbeitskosten
für diesen Service berechnet.

• Optional – Teile, für die das Customer Self Repair-Verfahren optional ist. Diese Teile sind auch für

Customer Self Repair ausgelegt. Wenn Sie jedoch den Austausch dieser Teile von HP vornehmen
lassen möchten, können bei diesem Service je nach den für Ihr Produkt vorgesehenen
Garantiebedingungen zusätzliche Kosten anfallen.

HINWEIS: Einige Teile sind nicht für Customer Self Repair ausgelegt. Um den Garantieanspruch des
Kunden zu erfüllen, muss das Teil von einem HP Servicepartner ersetzt werden. Im illustrierten Teilekatalog
sind diese Teile mit „No“ bzw. „Nein“ gekennzeichnet.

CSR-Teile werden abhängig von der Verfügbarkeit und vom Lieferziel am folgenden Geschäftstag
geliefert. Für bestimmte Standorte ist eine Lieferung am selben Tag oder innerhalb von vier Stunden gegen
einen Aufpreis verfügbar. Wenn Sie Hilfe benötigen, können Sie das HP technische Support Center

Customer self repair 8

anrufen und sich von einem Mitarbeiter per Telefon helfen lassen. Den Materialien, die mit einem CSR­Ersatzteil geliefert werden, können Sie entnehmen, ob das defekte Teil an HP zurückgeschickt werden
muss. Wenn es erforderlich ist, das defekte Teil an HP zurückzuschicken, müssen Sie dies innerhalb eines
vorgegebenen Zeitraums tun, in der Regel innerhalb von fünf (5) Geschäftstagen. Das defekte Teil muss
mit der zugehörigen Dokumentation in der Verpackung zurückgeschickt werden, die im Lieferumfang
enthalten ist. Wenn Sie das defekte Teil nicht zurückschicken, kann HP Ihnen das Ersatzteil in Rechnung
stellen. Im Falle von Customer Self Repair kommt HP für alle Kosten für die Lieferung und Rücksendung auf
und bestimmt den Kurier-/Frachtdienst.

Weitere Informationen über das HP Customer Self Repair Programm erhalten Sie von Ihrem Servicepartner
vor Ort. Informationen über das CSR-Programm in Nordamerika finden Sie auf der HP Website unter
(http://www.hp.com/go/selfrepair

).

Parts-only Warranty Service (Garantieservice
ausschließlich für Teile)

Ihre HP Garantie umfasst möglicherweise einen Parts-only Warranty Service (Garantieservice
ausschließlich für Teile). Gemäß den Bestimmungen des Parts-only Warranty Service stellt HP Ersatzteile
kostenlos zur Verfügung.

Für den Parts-only Warranty Service ist das CSR-Verfahren zwingend vorgegeben. Wenn Sie den
Austausch dieser Teile von HP vornehmen lassen, werden Ihnen die Anfahrt- und Arbeitskosten für diesen
Service berechnet.

Reparaciones del propio cliente

Los productos de HP incluyen muchos componentes que el propio usuario puede reemplazar (Customer
Self Repair, CSR) para minimizar el tiempo de reparación y ofrecer una mayor flexibilidad a la hora de
realizar sustituciones de componentes defectuosos. Si, durante la fase de diagnóstico, HP (o los
proveedores o socios de servicio de HP) identifica que una reparación puede llevarse a cabo mediante el
uso de un componente CSR, HP le enviará dicho componente directamente para que realice su
sustitución. Los componentes CSR se clasifican en dos categorías:

• Obligatorio: componentes para los que la reparación por parte del usuario es obligatoria. Si

solicita a HP que realice la sustitución de estos componentes, tendrá que hacerse cargo de los
gastos de desplazamiento y de mano de obra de dicho servicio.

• Opcional: componentes para los que la reparación por parte del usuario es opcional. Estos

componentes también están diseñados para que puedan ser reparados por el usuario. Sin embargo,
si precisa que HP realice su sustitución, puede o no conllevar costes adicionales, dependiendo del
tipo de servicio de garantía correspondiente al producto.

NOTA: Algunos componentes no están diseñados para que puedan ser reparados por el usuario. Para
que el usuario haga valer su garantía, HP pone como condición que un proveedor de servicios
autorizado realice la sustitución de estos componentes. Dichos componentes se identifican con la palabra
"No" en el catálogo ilustrado de componentes.

Según la disponibilidad y la situación geográfica, los componentes CSR se enviarán para que lleguen a
su destino al siguiente día laborable. Si la situación geográfica lo permite, se puede solicitar la entrega
en el mismo día o en cuatro horas con un coste adicional. Si precisa asistencia técnica, puede llamar al

Customer self repair 9

Centro de asistencia técnica de HP y recibirá ayuda telefónica por parte de un técnico. Con el envío de
materiales para la sustitución de componentes CSR, HP especificará si los componentes defectuosos
deberán devolverse a HP. En aquellos casos en los que sea necesario devolver algún componente a HP,
deberá hacerlo en el periodo de tiempo especificado, normalmente cinco días laborables. Los
componentes defectuosos deberán devolverse con toda la documentación relacionada y con el embalaje
de envío. Si no enviara el componente defectuoso requerido, HP podrá cobrarle por el de sustitución. En
el caso de todas sustituciones que lleve a cabo el cliente, HP se hará cargo de todos los gastos de envío
y devolución de componentes y escogerá la empresa de transporte que se utilice para dicho servicio.

Para obtener más información acerca del programa de Reparaciones del propio cliente de HP, póngase
en contacto con su proveedor de servicios local. Si está interesado en el programa para Norteamérica,
visite la página web de HP siguiente (http://www.hp.com/go/selfrepair

).

Servicio de garantía exclusivo de componentes

La garantía limitada de HP puede que incluya un servicio de garantía exclusivo de componentes. Según
las condiciones de este servicio exclusivo de componentes, HP le facilitará los componentes de repuesto
sin cargo adicional alguno.

Para este servicio de garantía exclusivo de componentes, es obligatoria la sustitución de componentes
por parte del usuario (CSR). Si solicita a HP que realice la sustitución de estos componentes, tendrá que
hacerse cargo de los gastos de desplazamiento y de mano de obra de dicho servicio.

Customer Self Repair

Veel onderdelen in HP producten zijn door de klant zelf te repareren, waardoor de reparatieduur tot een
minimum beperkt kan blijven en de flexibiliteit in het vervangen van defecte onderdelen groter is. Deze
onderdelen worden CSR-onderdelen (Customer Self Repair) genoemd. Als HP (of een HP Service Partner)
bij de diagnose vaststelt dat de reparatie kan worden uitgevoerd met een CSR-onderdeel, verzendt HP
dat onderdeel rechtstreeks naar u, zodat u het defecte onderdeel daarmee kunt vervangen. Er zijn twee
categorieën CSR-onderdelen:

• Verplicht: Onderdelen waarvoor reparatie door de klant verplicht is. Als u HP verzoekt deze

onderdelen voor u te vervangen, worden u voor deze service reiskosten en arbeidsloon in rekening
gebracht.

• Optioneel: Onderdelen waarvoor reparatie door de klant optioneel is. Ook deze onderdelen zijn

ontworpen voor reparatie door de klant. Als u echter HP verzoekt deze onderdelen voor u te
vervangen, kunnen daarvoor extra kosten in rekening worden gebracht, afhankelijk van het type
garantieservice voor het product.

OPMERKING: Sommige HP onderdelen zijn niet ontwikkeld voor reparatie door de klant. In verband
met de garantievoorwaarden moet het onderdeel door een geautoriseerde Service Partner worden
vervangen. Deze onderdelen worden in de geïllustreerde onderdelencatalogus aangemerkt met "Nee".

Afhankelijk van de leverbaarheid en de locatie worden CSR-onderdelen verzonden voor levering op de
eerstvolgende werkdag. Levering op dezelfde dag of binnen vier uur kan tegen meerkosten worden
aangeboden, indien dit mogelijk is gezien de locatie. Indien assistentie gewenst is, belt u een HP Service
Partner om via de telefoon technische ondersteuning te ontvangen. HP vermeldt in de documentatie bij het
vervangende CSR-onderdeel of het defecte onderdeel aan HP moet worden geretourneerd. Als het defecte
onderdeel aan HP moet worden teruggezonden, moet u het defecte onderdeel binnen een bepaalde

Customer self repair 10

periode, gewoonlijk vijf (5) werkdagen, retourneren aan HP. Het defecte onderdeel moet met de
bijbehorende documentatie worden geretourneerd in het meegeleverde verpakkingsmateriaal. Als u het
defecte onderdeel niet terugzendt, kan HP u voor het vervangende onderdeel kosten in rekening brengen.
Bij reparatie door de klant betaalt HP alle verzendkosten voor het vervangende en geretourneerde
onderdeel en kiest HP zelf welke koerier/transportonderneming hiervoor wordt gebruikt.

Neem contact op met een Service Partner voor meer informatie over het Customer Self Repair programma
van HP. Informatie over Service Partners vindt u op de HP website (http://www.hp.com/go/selfrepair

Garantieservice "Parts Only"

Het is mogelijk dat de HP garantie alleen de garantieservice "Parts Only" omvat. Volgens de bepalingen
van de Parts Only garantieservice zal HP kosteloos vervangende onderdelen ter beschikking stellen.

Voor de Parts Only garantieservice is vervanging door CSR-onderdelen verplicht. Als u HP verzoekt deze
onderdelen voor u te vervangen, worden u voor deze service reiskosten en arbeidsloon in rekening
gebracht.

).

Reparo feito pelo cliente

Os produtos da HP são projetados com muitas peças para reparo feito pelo cliente (CSR) de modo a
minimizar o tempo de reparo e permitir maior flexibilidade na substituição de peças com defeito. Se,
durante o período de diagnóstico, a HP (ou fornecedores/parceiros de serviço da HP) concluir que o
reparo pode ser efetuado pelo uso de uma peça CSR, a peça de reposição será enviada diretamente ao
cliente. Existem duas categorias de peças CSR:

• Obrigatória – Peças cujo reparo feito pelo cliente é obrigatório. Se desejar que a HP substitua

essas peças, serão cobradas as despesas de transporte e mão-de-obra do serviço.

• Opcional – Peças cujo reparo feito pelo cliente é opcional. Essas peças também são projetadas

para o reparo feito pelo cliente. No entanto, se desejar que a HP as substitua, pode haver ou não a
cobrança de taxa adicional, dependendo do tipo de serviço de garantia destinado ao produto.

OBSERVAÇÃO: Algumas peças da HP não são projetadas para o reparo feito pelo cliente. A fim de
cumprir a garantia do cliente, a HP exige que um técnico autorizado substitua a peça. Essas peças estão
identificadas com a marca "No" (Não), no catálogo de peças ilustrado.

Conforme a disponibilidade e o local geográfico, as peças CSR serão enviadas no primeiro dia útil após
o pedido. Onde as condições geográficas permitirem, a entrega no mesmo dia ou em quatro horas pode
ser feita mediante uma taxa adicional. Se precisar de auxílio, entre em contato com o Centro de suporte
técnico da HP para que um técnico o ajude por telefone. A HP especifica nos materiais fornecidos com a
peça CSR de reposição se a peça com defeito deve ser devolvida à HP. Nos casos em que isso for
necessário, é preciso enviar a peça com defeito à HP dentro do período determinado, normalmente
cinco (5) dias úteis. A peça com defeito deve ser enviada com a documentação correspondente no
material de transporte fornecido. Caso não o faça, a HP poderá cobrar a reposição. Para as peças de
reparo feito pelo cliente, a HP paga todas as despesas de transporte e de devolução da peça e
determina a transportadora/serviço postal a ser utilizado.

Para obter mais informações sobre o programa de reparo feito pelo cliente da HP, entre em contato com
o fornecedor de serviços local. Para o programa norte-americano, visite o site da HP
(http://www.hp.com/go/selfrepair

).

Customer self repair 11

Serviço de garantia apenas para peças

A garantia limitada da HP pode incluir um serviço de garantia apenas para peças. Segundo os termos
do serviço de garantia apenas para peças, a HP fornece as peças de reposição sem cobrar nenhuma
taxa.

No caso desse serviço, a substituição de peças CSR é obrigatória. Se desejar que a HP substitua essas
peças, serão cobradas as despesas de transporte e mão-de-obra do serviço.

Customer self repair 12

Customer self repair 13

Customer self repair 14

Customer self repair 15

Customer self repair 16

Illustrated parts catalog

Replaceable spare parts

The replaceable spare parts for the HP Modular Cooling System are listed in the following table.

Item Description Spare part

number

1 SPS–DISPLAY, OPERATOR ("Operator

display" on page 88)

2 SPS–HEAT EXCHANGER ("Heat exchanger

unit (HEX) with coupler" on page 59)

3 SPS–MCS, MGMT, MODULE

("Management module" on page 85)

395774-001 Optional2

395776-001 Optional2

395772-001 Optional2

Customer self
repair

Illustrated parts catalog 17

Item Description Spare part

number

4 SPS–TRANSFER SWITCH ("AC transfer

395773-001 Optional2

Customer self
repair

switch" on page 26)

5 SPS–CONTROLLER, WATER ("Water group

395771-001 Optional2

controller" on page 97)

6 SPS–SOLENOID, MAGNETIC VALVE

399037-001 Optional2

("Magnetic solenoid valve" on page 82)

7 SPS–CONDENSATE, PUMP & SENSORS

395775-001 Optional2
("Condensation pump and sensors" on
page 47)

8 SPS–FAN, MAIN ("Fan unit" on page 50) 395777-001 Optional2

9 SPS–HARDWARE KIT, MISC

407165-001 No3
("Miscellaneous hardware kit overview" on
page 113)

9A) Magnetic valve diaphragm and spring — —

9B) Flow meter — —

9C) Gasket* — —

10 SPS–COUPLING, MCS, HEX ("HEX

444000-001 Optional2

coupling" on page 77)

11 SPS–COUPLING, MCS, INLET ("Water inlet

444001-001 Optional2

coupling" on page 102)

12 SPS–KIT, FLOW METER, REPAIR ("Flow

441821-001 Optional2

meter sensor" on page 54)

13 SPS–VALVE, AIR BLEEDER ("Air bleeder

446971-001 Optional2

valve" on page 31)

14 SPS–SENSORS, TEMP, INLET/OUTLET

446970-001 Optional2
("Water temperature sensor" on page 107)

** SPS–KIT, DOOR RELEASE, AUTOMATIC

441822-001 Optional2
("Automatic door release" on page 38)

* Removal and replacement instructions are not included in this document.
** Not shown

1

Mandatory—Parts for which customer self repair is mandatory. If you request HP to replace these parts, you will be

charged for the travel and labor costs of this service.

2

Optional—Parts for which customer self repair is optional. These parts are also designed for customer self repair. If,
however, you require that HP replace them for you, there may or may not be additional charges, depending on the
type of warranty service designated for your product.

3

No—Some HP parts are not designed for customer self repair. In order to satisfy the customer warranty, HP requires
that an authorized service provider replace the part. These parts are identified as "No" in the Illustrated Parts
Catalog.

1

Mandatory: Obligatoire—Pièces pour lesquelles la réparation par le client est obligatoire. Si vous demandez à HP
de remplacer ces pièces, les coûts de déplacement et main d'œuvre du service vous seront facturés.

2

Optional: Facultatif—Pièces pour lesquelles la réparation par le client est facultative. Ces pièces sont également
conçues pour permettre au client d'effectuer lui-même la réparation. Toutefois, si vous demandez à HP de remplacer
ces pièces, l'intervention peut ou non vous être facturée, selon le type de garantie applicable à votre produit.

3

No: Non—Certaines pièces HP ne sont pas conçues pour permettre au client d'effectuer lui-même la réparation. Pour
que la garantie puisse s'appliquer, HP exige que le remplacement de la pièce soit effectué par un Mainteneur Agréé.
Ces pièces sont identifiées par la mention “Non” dans le Catalogue illustré.

Illustrated parts catalog 18

1

Mandatory: Obbligatorie—Parti che devono essere necessariamente riparate dal cliente. Se il cliente ne affida la
riparazione ad HP, deve sostenere le spese di spedizione e di manodopera per il servizio.

2

Optional: Opzionali—Parti la cui riparazione da parte del cliente è facoltativa. Si tratta comunque di componenti
progettati per questo scopo. Se tuttavia il cliente ne richiede la sostituzione ad HP, potrebbe dover sostenere spese
addizionali a seconda del tipo di garanzia previsto per il prodotto.

3

No: Non CSR—Alcuni componenti HP non sono progettati per la riparazione da parte del cliente. Per rispettare la
garanzia, HP richiede che queste parti siano sostituite da un centro di assistenza autorizzato. Tali parti sono
identificate da un “No” nel Catalogo illustrato dei componenti.

1

Mandatory: Zwingend—Teile, die im Rahmen des Customer Self Repair Programms ersetzt werden müssen. Wenn
Sie diese Teile von HP ersetzen lassen, werden Ihnen die Versand- und Arbeitskosten für diesen Service berechnet.

2

Optional: Optional—Teile, für die das Customer Self Repair-Verfahren optional ist. Diese Teile sind auch für
Customer Self Repair ausgelegt. Wenn Sie jedoch den Austausch dieser Teile von HP vornehmen lassen möchten,
können bei diesem Service je nach den für Ihr Produkt vorgesehenen Garantiebedingungen zusätzliche Kosten
anfallen.

3

No: Kein—Einige Teile sind nicht für Customer Self Repair ausgelegt. Um den Garantieanspruch des Kunden zu
erfüllen, muss das Teil von einem HP Servicepartner ersetzt werden. Im illustrierten Teilekatalog sind diese Teile mit
„No“ bzw. „Nein“ gekennzeichnet.

1

Mandatory: Obligatorio—componentes para los que la reparación por parte del usuario es obligatoria. Si solicita a
HP que realice la sustitución de estos componentes, tendrá que hacerse cargo de los gastos de desplazamiento y de
mano de obra de dicho servicio.

2

Optional: Opcional— componentes para los que la reparación por parte del usuario es opcional. Estos
componentes también están diseñados para que puedan ser reparados por el usuario. Sin embargo, si precisa que
HP realice su sustitución, puede o no conllevar costes adicionales, dependiendo del tipo de servicio de garantía
correspondiente al producto.

3

No: No—Algunos componentes no están diseñados para que puedan ser reparados por el usuario. Para que el
usuario haga valer su garantía, HP pone como condición que un proveedor de servicios autorizado realice la
sustitución de estos componentes. Dichos componentes se identifican con la palabra “No” en el catálogo ilustrado de
componentes.

1

Mandatory: Verplicht—Onderdelen waarvoor Customer Self Repair verplicht is. Als u HP verzoekt deze onderdelen
te vervangen, komen de reiskosten en het arbeidsloon voor uw rekening.

2

Optional: Optioneel—Onderdelen waarvoor reparatie door de klant optioneel is. Ook deze onderdelen zijn
ontworpen voor reparatie door de klant. Als u echter HP verzoekt deze onderdelen voor u te vervangen, kunnen
daarvoor extra kosten in rekening worden gebracht, afhankelijk van het type garantieservice voor het product.

3

No: Nee—Sommige HP onderdelen zijn niet ontwikkeld voor reparatie door de klant. In verband met de
garantievoorwaarden moet het onderdeel door een geautoriseerde Service Partner worden vervangen. Deze
onderdelen worden in de geïllustreerde onderdelencatalogus aangemerkt met "Nee".

1

Mandatory: Obrigatória—Peças cujo reparo feito pelo cliente é obrigatório. Se desejar que a HP substitua essas
peças, serão cobradas as despesas de transporte e mão-de-obra do serviço.

2

Optional: Opcional—Peças cujo reparo feito pelo cliente é opcional. Essas peças também são projetadas para o
reparo feito pelo cliente. No entanto, se desejar que a HP as substitua, pode haver ou não a cobrança de taxa
adicional, dependendo do tipo de serviço de garantia destinado ao produto.

3

No: Nenhuma—Algumas peças da HP não são projetadas para o reparo feito pelo cliente. A fim de cumprir a
garantia do cliente, a HP exige que um técnico autorizado substitua a peça. Essas peças estão identificadas com a
marca “No” (Não), no catálogo de peças ilustrado.

Illustrated parts catalog 19

Flow meter repair

There are two different flow meter types, depending on your MCS model. You should be able to discern
which type you have, based on the label on the rear door of your MCS unit.

Illustrated parts catalog 20

The Type 1 flow meter has a round body, and is no longer used in current MCS models.

The Type 2 flow meter has a square body and ships installed in all current MCS models.

There are two scenarios when repairing your flow meter:

• You currently have a Type 1 flow meter that you will remove and replace with a Type 2 flow meter.

For this type of repair, you will order the Miscellaneous Hardware Kit and have a trained technician
complete your repair.

-or-

• You have a Type 2 flow meter and will remove and replace the flow meter paddle-wheel sensor at

the top of your flow meter. For this type of repair, you will order the Flow Meter Paddle-Wheel
Sensor Kit and can complete the repair yourself.

Illustrated parts catalog 21

Removal and replacement procedures

Removal and replacement procedure overview

This section provides guidance for removing and replacing the HP Modular Cooling System (MCS) spare
parts.

Follow the instructions carefully to ensure proper installation of the new spare part.

IMPORTANT: As you are removing the HP Modular Cooling System components, be sure to

Viewing the spare replacement video

retain the screws in a safe place and separate them according to their type.

Because of the difficulty of removing and replacing spare parts, HP recommends watching the HP
Modular Cooling System Spare Replacement video. This video provides further explanation and detail of
replacement strategies and techniques that might be helpful when attempting to remove and replace spare
parts. You can access the video on the HP website (http://www.hp.com/go/mcs

1. Select HP Modular Cooling System.

2. Under Related Links, select HP Support and Drivers.

3. Select HP Modular Cooling System.

4. Under Resources for Modular Cooling System, select Customer self repair steps (videos/animations).

5. Select Remove/Replace Videos.

6. Select the appropriate spare part from the list on the left-hand side.

Customer self repair required tools

The following tools are required for each spares kit removal and replacement procedures:

• AC transfer switch

o T-25 Torx driver

o Small Flathead screwdriver

• Air bleeder valve

).

o T-25 Torx driver

o Pliers

o Water hose fitting wrench (included with your original MCS unit)

o Counter hold wrench (included with your original MCS unit)

• Automatic door release

o 3-mm Allen wrench

Removal and replacement procedures 22

o T-25 Torx driver

o Wire cutters

• Condensation pump and sensors

o T-25 Torx driver

o Phillips screwdriver

• Fan unit

o T-25 Torx driver

• Flow meter paddle-wheel sensor

o T-25 Torx driver

o Wire cutters

o Water hose fitting wrench (included with your original MCS unit)

o Counter hold wrench (included with your original MCS unit)

• Heat exchanger unit (HEX) with coupler

o T-25 Torx driver

o Water hose fitting wrench (included with your original MCS unit)

o Counter hold wrench (included with your original MCS unit)

• Heat exchanger unit (HEX) with ball valves

o Adjustable wrench or pipe wrench

o T-25 Torx driver

• HEX coupling

o T-25 Torx driver

o Water hose fitting wrench (included with your original MCS unit)

o Counter hold wrench (included with your original MCS unit)

o Flathead screwdriver

o Utility knife

• Magnetic solenoid valve

o T-25 Torx driver

o Phillips screwdriver

• Management module

No tools are required for this procedure.

• Operator display

o 8-mm socket

o Small Flathead screwdriver

• Water group controller

o T-25 Torx driver

o Flathead screwdriver

o 8-mm socket

• Water inlet coupling

Removal and replacement procedures 23

o 5-mm Allen wrench

• Water temperature sensor

o T-25 Torx driver

o Phillips screwdriver

o (2) 18-mm wrench

o Wire cutters

Safety considerations

Rack warnings and cautions

Before performing service procedures, review the following safety information.

Before installing a spare kit, be sure that you understand the following warnings and cautions.

WARNING: You must follow the removal and replacement instructions listed in the site

preparation guide, the user guide, and the maintenance and service guide. Failure to follow
the instructions listed in these guides can void your warranty and service contract.

WARNING: To reduce the risk of electric shock or damage to the equipment, use extreme

caution when removing and replacing components that involve water around the electrical
wires and unsecured power inlet box. There is great risk of electrical shock when water is used
near electricity.

IMPORTANT: To reduce the risk of the servers overheating, open all of the rack doors of each

rack attached to the MCS unit while completing the following procedures in order to increase
air flow within the rack.

IMPORTANT: While the most important cautions and warnings have been included in this

document, consult the site preparation guide and the user guide provided with the original unit
for a complete list of cautions and warnings.

Preparation procedures

Powering down the MCS unit

Before you perform certain service procedures, perform one or both of the following procedures.

1. Open the front MCS door.

2. Turn off the AC1 and AC2 breakers on the AC transfer switch.

3. Open the rear MCS door.

Removal and replacement procedures 24

WARNING: To reduce the risk of electric shock or damage to the equipment:

• Do not disable the power cord grounding plug. The grounding plug is an important safety

feature.

• Plug the power cord into a grounded (earthed) electrical outlet that is easily accessible at all

times.

• Unplug the power cord from the power supply to disconnect power to the equipment.

• Do not route the power cord where it can be walked on or pinched by items placed against

it. Pay particular attention to the plug, electrical outlet, and the point where the cord

4. Disconnect the two AC power cables from the power connectors, labeled Primary and Secondary,

extends from the storage system.

on the power inlet box.

5. Disconnect the network cable from the RJ-45 connector on the power inlet box.

Shutting off the water

1. Shut off the water flowing into the MCS unit at the facility-side shut-off valve.

Removal and replacement procedures 25

2. Confirm that no water is flowing into the MCS unit.

AC transfer switch

The AC transfer switch is located at the bottom front of the MCS unit.

The following tools are required for installation:

• T-25 Torx driver

• Small Flathead screwdriver

Removing the AC transfer switch

1. Power down the MCS unit ("Powering down the MCS unit" on page 24).

2. Open the front MCS door.

3. Slide the metal AC transfer switch box out toward you on the sliding rails.

Removal and replacement procedures 26

4. Using a T-25 Torx driver, remove the four Torx screws securing the AC transfer switch chassis to the

water group controller chassis. The transfer switch chassis cannot be completely removed yet
because the cables are still connected.

5. Disconnect the green and yellow ground bonding wires from the water group controller.

6. Disconnect the electrical power cables from the rear of the AC transfer switch.

Removal and replacement procedures 27

a. Disconnect the three large cables, starting from the left and moving to the right, by inserting a

small flathead screwdriver in between the cable connection and the latch, and pulling the cable
out from the connector.

b. Disconnect the three small cables, starting from the left and moving to the right, by pressing the

small tab on the bottom of each small cable and pulling it out from the connector.

After you have disconnected all of the cables, the transfer switch chassis is free from restraint and can be
removed from the water group controller chassis.

To replace this component, see "Replacing the AC transfer switch (on page 28)."

Replacing the AC transfer switch

1. Connect the green and yellow ground bonding wires to the water group controller.

Removal and replacement procedures 28

2. Connect the electrical power cables from the MCS unit to the AC transfer switch.

a. Connect the three small cables, starting from the right and moving to the left, by pressing the tab

on the bottom of each cable and pushing it into the connector.

Removal and replacement procedures 29

b. Connect the three large cables, starting from the right and moving to the left, by pushing the

cable into the connector.

3. Using a T-25 Torx driver, secure the AC transfer switch chassis to the water group controller chassis

by inserting four Torx screws.

CAUTION: To prevent damage to the cables and ensure proper fit of the transfer switch

chassis, be sure to route all cables through the U-shaped opening in the rear of the chassis.

Removal and replacement procedures 30

4. Slide the metal AC transfer switch box back into the MCS unit on the sliding rails.

5. Complete the operation checklist (on page 111).

Air bleeder valve

The air bleeder valve is located inside the MCS unit, centered at the top of the unit.

The following tools are required for installation:

• T-25 Torx driver

• Pliers

• Water hose fitting wrench (included with your original MCS unit)

• Counter hold wrench (included with your original MCS unit)

Removing the air bleeder valve

1. Shut off the water flowing into the MCS unit. ("Shutting off the water" on page 25)

2. Remove the top fan unit. ("Removing the fan unit" on page 51)

3. Remove the top heat exchanger unit. ("Removing the heat exchanger unit with couplers" on page

59)

Removal and replacement procedures 31

4. Reach into the access panel cut-out.

5. Using a pair of pliers, unscrew the air bleeder valve from the check valve.

6. Remove the air bleeder valve from the MCS unit.

To replace this component, see "Replacing the air bleeder valve (on page 32)."

Replacing the air bleeder valve

1. Reach into the access panel cut-out and align the air bleeder valve to the check valve.

2. Firmly hand-tighten the air bleeder valve.

Removal and replacement procedures 32

3. Slightly open the top vent of the air bleeder valve, approximately 3/4 turn, to allow for air flow.

4. Replace the top heat exchanger unit. ("Replacing the heat exchanger unit with couplers" on page

63)

5. Replace the top fan unit. ("Replacing the fan unit" on page 52)

6. Restore water flow to the MCS unit. ("Restoring water flow" on page 112)

7. Complete the operation checklist (on page 111).

Air deflector plate

The air deflector plate is not a spare part. The removal and replacement instructions for the air deflector
plate are provided so that you can access other components.

Removing the air deflector plate

No tools are required for this procedure.

1. Loosen the two thumbscrews securing the air deflector plate to the MCS unit.

2. Disconnect the green and yellow ground bonding wire.

Removal and replacement procedures 33

3. Lift the air deflector plate up, tilt it to an angle, and pull it out toward you.

To replace this component, see "Replacing the air deflector plate (on page 34)."

Replacing the air deflector plate

1. Reattach the ground bonding wires to the air deflector plate.

2. Align the two screw holes on the air deflector plate to the two screw holes inside the MCS unit.

3. Secure the air deflector plate to the MCS unit by tightening the two thumbscrews in the two screw

holes.

Air sealing plate

The air sealing plate is not a spare part. The removal and replacement instructions for the air sealing
plate are provided so that you can access other components.

Removal and replacement procedures 34

No tools are required for this procedure.

Removing the air sealing plate

1. Disconnect the condensation hose from the condensation pump by pressing in the plastic collar quick

connect on the condensation pump.

2. Loosen the two thumbscrews securing the air sealing plate to the MCS unit.

Removal and replacement procedures 35

3. Slide the air sealing plate out of the MCS unit.

To replace this component, see "Replacing the air sealing plate (on page 36)."

Replacing the air sealing plate

1. Slide the air sealing plate into the MCS unit.

Removal and replacement procedures 36

2. Secure the air sealing plate to the MCS unit by tightening the two thumbscrews.

3. Connect the condensation hose to the condensation pump by inserting it into the plastic collar quick

connect on the condensation pump.

Removal and replacement procedures 37

Automatic door release

The automatic door release kits are located on the front and rear doors of the rack attached to the MCS
unit.

The following tools are required for installation:

• 3-mm Allen wrench

• T-25 Torx driver

• Wire cutters

Removing the front automatic door release

1. Unplug the electromagnetic lock cable from the panel connector on the MCS unit.

Removal and replacement procedures 38

2. Using an Allen wrench, remove the two black cap screws securing the electromagnetic lock to the

electromagnetic lock bracket.

3. Remove the electromagnetic lock and cable from the rack.

To replace this component, see "Replacing the front automatic door release (on page 39)."

Replacing the front automatic door release

1. Align the electromagnetic lock to the electromagnetic lock bracket.

2. Using an Allen wrench, insert and tighten two black cap screws to secure the electromagnetic lock to

the electromagnetic lock bracket.

Removal and replacement procedures 39

3. Route the magnetic lock cable down through front extension channel, across the front of the rack,

and plug it into the panel connector on the MCS unit.

Removal and replacement procedures 40

Removing the rear automatic door release

1. Unplug the top and bottom electromagnetic lock cables from the extension lock cable.

NOTE: Be sure to note the location of the electromagnetic brackets prior to removal.

Removal and replacement procedures 41

2. Using a T-25 Torx driver, remove the four screws securing the upper and lower electromagnetic lock

brackets to the rack chassis.

3. Using an Allen wrench, remove the two black cap screws securing each electromagnetic lock to its

electromagnetic lock bracket.

4. Remove the electromagnetic locks and cables from the rack.

To replace this component, see "Replacing the rear automatic door release (on page 42)."

Replacing the rear automatic door release

1. Align the electromagnetic locks to the electromagnetic lock brackets.

Removal and replacement procedures 42

2. Using an Allen wrench, insert and tighten two black cap screws to secure each electromagnetic lock

to its electromagnetic lock bracket.

3. Install the top electromagnetic lock bracket to the rack chassis in the location you noted during

removal.

a. Align the electromagnetic lock assembly to the rack chassis in the location you noted during

removal.

b. Using a T-25 Torx driver, insert and tighten two M5.5 self-tapping screws into the inner row of

rack holes to secure the electromagnetic lock assembly to the rack chassis.

4. Repeat step 3 for the bottom electromagnetic lock bracket.

Removal and replacement procedures 43

5. Route the magnetic lock cable through the rear extension channel, across the rack, and plug it into

the panel connector on the MCS unit.

Bottom fan unit

The removal and replacement instructions for the bottom fan unit are provided so that you can access
other components. If you are replacing the fan unit, see Fan unit (on page 50).

Removing the bottom fan unit

No tools are required for this procedure.

1. Open the rear MCS door.

2. Using a T-25 Torx driver, remove the four Torx screws securing the horizontal shipping bracket to the

MCS frame.

Removal and replacement procedures 44

3. Loosen the two thumbscrews on the bottom of the fan unit.

CAUTION: The fan unit weighs 16.8 kg (37 lb). Use extra caution when removing and

replacing the top fan unit because it might be higher than your shoulders and is heavy and

4. Pull the fan unit out toward you, and remove it from the MCS unit.

awkward to lift.

To replace this component, see "Replacing the bottom fan unit (on page 45)."

Replacing the bottom fan unit

1. Align the fan unit to the sliding rails.

CAUTION: The fan unit weighs 16.8 kg (37 lb). Use extra caution when removing and

replacing the top fan unit because it might be higher than your shoulders and is heavy and
awkward to lift.

Removal and replacement procedures 45

2. Slide the bottom fan unit inside the MCS unit on the sliding rails.

3. Tighten the two thumbscrews to secure the fan unit to the MCS frame.

Removal and replacement procedures 46

4. Using a T-25 Torx driver, secure the horizontal shipping bracket to the MCS unit by inserting four

Torx screws.

Condensation pump and sensors

The condensation pump and sensors are components of the water group located at the bottom interior of
the MCS unit.

The following tools are required for installation:

• T-25 Torx driver

• Phillips screwdriver

Removing the condensation pump and sensors

1. Power down the MCS unit ("Powering down the MCS unit" on page 24).

2. Remove the bottom fan unit ("Removing the bottom fan unit" on page 44).

3. Relocate the power inlet box ("Relocating the power inlet box" on page 93).

4. Remove the air sealing plate ("Removing the air sealing plate" on page 35).

Removal and replacement procedures 47

5. Disconnect the AC power cable from the condensation pump.

6. Disconnect the two sensor connections from the condensation pump.

Removal and replacement procedures 48

7. Loosen the thumbscrew on the bottom of the condensation pump securing the condensation pump to

the MCS unit (1), and lift the condensation pump from the MCS unit (2).

To replace the component, see "Replacing the condensation pump and sensors (on page 49)."

Replacing the condensation pump and sensors

1. Align the condensation pump thumbscrew to the hole inside the MCS unit (1), and tighten the

thumbscrew on the bottom of the condensation pump to secure it to the MCS unit (2).

Removal and replacement procedures 49

2. Connect the two sensor connectors to the condensation pump.

3. Connect the AC power cable to the condensation pump.

4. Replace the air sealing plate ("Replacing the air sealing plate" on page 36).

5. Relocate the power inlet box back into position ("Relocating the power inlet box back into position"

on page 95).

6. Replace the bottom fan unit ("Replacing the bottom fan unit" on page 45).

7. Complete the operation checklist (on page 111).

Fan unit

The three fan units are located at the rear of the MCS unit.

Removal and replacement procedures 50

You can replace the fan units during operation.

The following tools are required for installation:

• T-25 Torx driver

Removing the fan unit

1. Open the rear MCS door.

NOTE: The number of horizontal brackets varies depending on the position of the fan unit (top,

2. Using a T-25 Torx driver, remove the four Torx screws securing the horizontal shipping bracket to the

middle, or bottom).

MCS frame.

Removal and replacement procedures 51

3. Loosen the two thumbscrews on the bottom of the fan unit.

CAUTION: The fan unit weighs 16.8 kg (37 lb). Use extra caution when removing and

replacing the top fan unit because it might be higher than your shoulders and is heavy and

4. Pull the fan unit out toward you, and remove it from the MCS unit.

awkward to lift.

To replace this component, see "Replacing the fan unit (on page 52)."

Replacing the fan unit

1. Align the fan unit to the sliding rails.

CAUTION: The fan unit weighs 16.8 kg (37 lb). Use extra caution when removing and

replacing the top fan unit because it might be higher than your shoulders and is heavy and
awkward to lift.

Removal and replacement procedures 52

2. Slide the fan unit onto the sliding rails inside the MCS unit.

3. Tighten the two thumbscrews to secure the fan unit to the MCS frame.

NOTE: The number of horizontal brackets varies depending on the position of the fan unit (top,

middle, or bottom).

Removal and replacement procedures 53

4. Using a T-25 Torx driver, secure the horizontal shipping bracket to the MCS unit by inserting four

Torx screws.

5. Complete the operation checklist (on page 111).

Flow meter sensor

The flow meter sensor is a component of the water group located at the bottom interior of the MCS unit.

The following tools are required for installation:

• T-25 Torx driver

• Wire cutters

• Water hose fitting wrench (included with your original MCS unit)

• Counter hold wrench (included with your original MCS Unit)

Removing the flow meter paddle-wheel sensor

1. Power down the MCS unit. ("Powering down the MCS unit" on page 24)

2. Shut off the water flowing into the MCS unit. ("Shutting off the water" on page 25)

3. Remove the bottom fan unit. ("Removing the bottom fan unit" on page 44)

Removal and replacement procedures 54

4. Relocate the power inlet box. ("Relocating the power inlet box" on page 93)

5. Remove the air sealing plate. ("Removing the air sealing plate" on page 35)

6. Remove the air deflector plate. ("Removing the air deflector plate" on page 33)

7. Remove the condensation pump and sensors. ("Removing the condensation pump and sensors" on

page 47)

8. Remove the AC transfer switch. ("Removing the AC transfer switch" on page 26)

9. Remove the plastic lock washer from above the paddle-wheel sensor.

10. Unscrew the plastic screw cap securing the paddle-wheel sensor to the flow meter.

11. Lift the paddle-wheel sensor up and off the flow meter.

Removal and replacement procedures 55

12. Using the wire cutters, cut the cable connected to the paddle-wheel sensor and remove the sensor

from the MCS unit.

13. Disconnect the paddle-wheel sensor cable connector, labeled X14, from the water group controller

and pull the cable completely out of the MCS unit.

To replace this component, see "Replacing the flow meter paddle-wheel sensor (on page 57)."

Removal and replacement procedures 56

Replacing the flow meter paddle-wheel sensor

1. Insert the keyed paddle-wheel sensor into the top of the flow meter.

2. Screw on the plastic screw cap to secure the paddle-wheel sensor to the flow meter.

Removal and replacement procedures 57

3. Replace the plastic lock washer above the paddle-wheel sensor.

4. Route the paddle-wheel sensor cable through to the front of the MCS unit.

5. Connect the paddle-wheel sensor cable connector to the X14 connector on the water group

controller.

6. Replace the AC transfer switch ("Replacing the AC transfer switch" on page 28).

7. Replace the condensation pump and sensors ("Replacing the condensation pump and sensors" on

page 49).

8. Replace the air deflector plate ("Replacing the air deflector plate" on page 34).

9. Replace the bottom fan unit ("Replacing the bottom fan unit" on page 45).

10. Restore water flow to the MCS unit ("Restoring water flow" on page 112).

11. Complete the operation checklist (on page 111).

Removal and replacement procedures 58

Heat exchanger unit (HEX) with coupler

The three heat exchanger units are located on the front of the MCS unit.

You can replace the HEX units during operation.

The following tools are required for installation:

• T-25 Torx driver

• Water hose fitting wrench (included with your original MCS unit)

• Counter hold wrench (included with your original MCS unit)

Removing the heat exchanger unit with couplers

NOTE: For this procedure, remove the fan unit seated directly behind the heat exchanger unit

1. Remove the fan unit ("Removing the fan unit" on page 51).

2. Remove the air deflector plate ("Removing the air deflector plate" on page 33).

you will remove.

NOTE: The heat exchanger units are deep-seated within the MCS unit. To access the

connections described in the following steps, extend your arm inside the MCS unit until you
come in contact with the appropriate connectors.

Removal and replacement procedures 59

3. Disconnect the temperature sensor connector from the heat exchanger unit.

4. Using the counter hold wrench to hold the fitting in place and the water hose fitting wrench to loosen

the water hose (both wrenches are included with your original MCS unit), disconnect the In and Out
water hoses from the heat exchanger unit.

Removal and replacement procedures 60

5. Disconnect the condensation hose from the heat exchanger unit.

6. Disconnect the green and yellow ground bonding wire grounding the heat exchanger unit to the

MCS unit.

7. Open the front MCS door.

IMPORTANT: Keep the Torx screws separated according to their thread type and note which

thread type came from which hole location on the shipping bracket.

8. Remove the two heat exchanger unit shipping brackets.

a. Using a T-25 Torx driver, remove the four Torx screws securing the heat exchanger unit shipping

brackets to the MCS frame (1).

b. Using a T-25 Torx driver, remove the four Torx screws securing the heat exchanger unit shipping

brackets to the heat exchanger unit (2).

Removal and replacement procedures 61

c. Remove the heat exchanger unit shipping brackets from the MCS unit (3).

CAUTION: The heat exchanger unit weighs 23.6 kg (52 lb) with the additional weight of the

water. Use extra caution when removing and replacing the top heat exchanger unit because it
might be higher than your shoulders and is heavy and awkward to lift.

Removal and replacement procedures 62

9. Pull the heat exchanger unit out toward you.

To replace this component, see "Replacing the heat exchanger unit ("Replacing the heat exchanger unit

with couplers" on page 63)."

Replacing the heat exchanger unit with couplers

CAUTION: The heat exchanger unit weighs 23.6 kg (52 lb) with the additional weight of the

water. Use extra caution when removing and replacing the top heat exchanger unit because it
might be higher than your shoulders and is heavy and awkward to lift.

Removal and replacement procedures 63

1. Insert the new heat exchanger unit into the same position as the heat exchanger unit you removed.

IMPORTANT: Keep the Torx screws separated according to their thread type and note which

thread type came from which hole location on the shipping bracket.

2. Install the two heat exchanger unit shipping brackets.

a. Align the heat exchanger unit shipping brackets to the screw holes on the heat exchanger unit

and the MCS frame (1).

b. Using a T-25 Torx driver, secure the two heat exchanger unit shipping brackets to the heat

exchanger unit by inserting and tightening four Torx screws (2).

Removal and replacement procedures 64

c. Using a T-25 Torx driver, secure the two shipping brackets to the MCS frame by inserting and

tightening four Torx screws (3).

3. Open the rear MCS door.

Removal and replacement procedures 65

4. Connect the green and yellow ground bonding wire to the heat exchanger unit.

5. Connect the condensation hose to the heat exchanger unit.

Removal and replacement procedures 66

6. Using the counter hold wrench to hold the fitting in place and the water hose fitting wrench to tighten

the water hose (both wrenches are included with your original MCS unit), connect the In and Out
water hoses to the heat exchanger unit.

7. Connect the temperature sensor connector to the heat exchanger unit.

8. Replace the air deflector plate ("Replacing the air deflector plate" on page 34).

9. Replace the fan unit ("Replacing the fan unit" on page 52).

Complete the operation checklist (on page 111).

Heat exchanger unit (HEX) with ball valve

The three heat exchanger units are located on the front of the MCS unit.

Removal and replacement procedures 67

You can replace the HEX units during operation.

The following tools are required for installation:

• T-25 Torx driver

• Adjustable wrench or pipe wrench

Removing the heat exchanger unit with ball valves

NOTE: For this procedure, remove the fan unit seated directly behind the heat exchanger unit

1. Remove the fan unit ("Removing the fan unit" on page 51).

2. Remove the air deflector plate ("Removing the air deflector plate" on page 33).

3. Disconnect the temperature sensor connector from the HEX unit.

you will remove.

NOTE: The heat exchanger units are deep-seated within the MCS unit. To access the

connections described in the following steps, extend your arm inside the MCS unit until you
come in contact with the appropriate connectors.

Removal and replacement procedures 68

4. Disconnect the condensation hose from the HEX unit.

5. Disconnect the green and yellow ground bonding wire grounding the HEX unit to the MCS unit.

6. Close the two ball valves inside the HEX unit.

Removal and replacement procedures 69

7. Close the two ball valves on the hose assemblies attached to the HEX unit.

8. Using and adjustable wrench or a pipe wrench, disconnect the two ball valve hose assemblies from

the HEX unit.

9. Wipe up any excess water from the hoses.

10. Open the front MCS door.

IMPORTANT: Keep the Torx screws separated according to their thread type and note which

thread type came from which hole location on the shipping bracket.

11. Remove the two HEX unit shipping brackets.

a. Using a T-25 Torx driver, remove the four Torx screws securing the HEX unit shipping brackets to

the MCS frame (1).

b. Using a T-25 Torx driver, remove the four Torx screws securing the HEX unit shipping brackets to

the heat exchanger unit (2).

Removal and replacement procedures 70

c. Remove the HEX unit shipping brackets from the MCS unit (3).

CAUTION: The heat exchanger unit weighs 23.6 kg (52 lb) with the additional weight of the

water. Use extra caution when removing and replacing the top heat exchanger unit because it
might be higher than your shoulders and is heavy and awkward to lift.

Removal and replacement procedures 71

12. Pull the HEX unit out toward you.

To replace this component, see "Replacing the heat exchanger unit with ball valves (on page 72)."

Replacing the heat exchanger unit with ball valves

CAUTION: The heat exchanger unit weighs 23.6 kg (52 lb) with the additional weight of the

water. Use extra caution when removing and replacing the top heat exchanger unit because it
might be higher than your shoulders and is heavy and awkward to lift.

Removal and replacement procedures 72

1. Insert the new HEX unit into the same position as the HEX unit you removed.

IMPORTANT: Keep the Torx screws separated according to their thread type and note which

thread type came from which hole location on the shipping bracket.

2. Install the two HEX unit shipping brackets.

a. Align the HEX unit shipping brackets to the screw holes on the HEX unit and the MCS frame (1).

b. Using a T-25 Torx driver, secure the two HEX unit shipping brackets to the heat exchanger unit

by inserting and tightening four Torx screws (2).

Removal and replacement procedures 73

c. Using a T-25 Torx driver, secure the two HEX unit shipping brackets to the MCS frame by

inserting and tightening four Torx screws (3).

3. Open the rear MCS door.

Removal and replacement procedures 74

4. Connect the green and yellow ground bonding wire to the HEX unit.

5. Connect the condensation hose to the HEX unit.

Removal and replacement procedures 75

6. Using an adjustable wrench or a pipe wrench, connect the two ball valve hose assemblies to the

HEX unit.

7. Connect the temperature sensor connector to the HEX unit.

8. Open the ball valves inside the HEX unit.

Removal and replacement procedures 76

9. Open the ball valves on the hose assemblies.

10. Confirm that water is flowing through the ball valve couplers, by touching the couplers. The couplers

should be cold.

11. Replace the hose insulation over the couplers.

12. Replace the air deflector plate ("Replacing the air deflector plate" on page 34).

13. Replace the fan unit ("Replacing the fan unit" on page 52).

14. Complete the operation checklist (on page 111).

HEX coupling

The three HEX couplings are located at the rear of each HEX unit iinside the MCS unit.

The following tools are required for installation:

• T-25 Torx driver

• Water hose fitting wrench (included with your original MCS unit)

• Counter hold wrench (included with your original MCS unit)

• Flathead screwdriver

• Utility knife

Removal and replacement procedures 77

Removing the HEX coupling

1. Shut off the water flowing into the MCS unit. ("Shutting off the water" on page 25)

2. Remove the corresponding fan unit. ("Removing the fan unit" on page 51)

3. Remove the corresponding air deflector plate. ("Removing the air deflector plate" on page 33)

4. Disconnect the temperature sensor cable from the heat exchanger unit.

5. Slide back the insulation on either the In or Out water hose.

6. Using the water hose fitting wrench and the counter hold wrench, disconnect either the In or Out

water hose from the heat exchanger unit.

Removal and replacement procedures 78

7. Using a flathead screwdriver, loosen the hose from the HEX coupling.

8. Using a utility knife, carefully trim approximately 0.64 cm (0.25 in) off the water hose.

Removal and replacement procedures 79

9. Remove the HEX coupling from the water hose.

To replace this component, see "Replacing the HEX coupling (on page 80)."

Replacing the HEX coupling

1. Insert the HEX coupling into the water hose.

Removal and replacement procedures 80

2. Using a flathead screwdriver, tighten the hose clamp.

3. Connect the HEX coupling to the heat exchanger unit.

4. Using the water hose fitting wrench and the counter hold wrench, reconnect the appropriate In or

Out water hose to the heat exchanger unit.

5. Confirm that the HEX coupling is fully engaged between the heat exchanger bulkhead and the

coupling nut.

Removal and replacement procedures 81

6. Reconnect the temperature sensor cable to the heat exchanger unit.

7. Slide the insulation back in place on the In or Out water hose up against the coupling.

8. Replace the air deflector plate ("Replacing the air deflector plate" on page 34).

9. Replace the fan unit ("Replacing the fan unit" on page 52).

10. Restore water flow to the MCS unit ("Restoring water flow" on page 112).

11. Complete the operation checklist (on page 111).

Magnetic solenoid valve

The magnetic solenoid valve is a component of the water group located at the bottom interior of the MCS
unit.

The following tools are required for installation:

• T-25 Torx driver

• Phillips screwdriver

Removing the magnetic solenoid valve

1. Power down the MCS unit ("Powering down the MCS unit" on page 24).

Removal and replacement procedures 82

2. Remove the bottom fan unit ("Removing the bottom fan unit" on page 44).

3. Remove the air deflector plate ("Removing the air deflector plate" on page 33).

4. Adjust the water hoses connected to the rear of the bottom heat exchanger unit and hold them out of

the way to reach the magnetic solenoid on the valve. This process can be difficult. If you struggle
excessively, disconnect the In and Out water hoses on the back of the bottom heat exchanger unit
using the counter hold wrench and the water hose fitting wrench.

5. On the magnetic solenoid valve, release the silver retainer tab (1), and remove the magnetic

solenoid from the valve post (2).

6. Using a Phillips screwdriver, remove the Phillips screw securing the electrical connector to the

magnetic solenoid.

To replace the component, see "Replacing the magnetic solenoid valve (on page 84)."

Removal and replacement procedures 83

Replacing the magnetic solenoid valve

1. Using a Phillips screwdriver, connect the electrical connector from the MCS unit to the magnetic

solenoid by inserting and tightening one Phillips screw.

2. Adjust the water hoses connected to the rear of the bottom heat exchanger unit and hold them out of

the way to reach the solenoid valve post. This process can be difficult. If you struggle excessively,
disconnect the In and Out water hoses connected to the bottom heat exchanger unit using the
counter hold wrench and the water hose fitting wrench.

3. Place the magnetic solenoid back on the valve post (1), and press down until the silver retainer tab

locks the magnetic solenoid in place on the valve (2).

4. Replace the air deflector plate ("Replacing the air deflector plate" on page 34).

5. Replace the bottom fan unit ("Replacing the bottom fan unit" on page 45).

6. Complete the operation checklist (on page 111).

Removal and replacement procedures 84

Management module

The management module is located on the inside of the front door of the MCS unit.

Removing the management module

No tools are required for this procedure.

1. Power down the MCS unit ("Powering down the MCS unit" on page 24).

2. Open the front MCS door.

3. Disconnect the electrical cables from the management module.

Removal and replacement procedures 85

4. Slide the management module off of the mounting bracket, and remove it from the inside of the front

MCS door.

To replace this component, see "Replacing the management module (on page 86)."

Replacing the management module

1. Slide the management module onto the mounting bracket until it locks in place.

CAUTION: To avoid damage to the management module connectors, do not allow the cables

to pull on the management module connectors.

Removal and replacement procedures 86

2. Connect the electrical cables from the MCS unit to the management module.

3. Power on the management module.

4. Press and hold the C key for five seconds to confirm the configuration settings.

5. Complete the operation checklist (on page 111).

Removal and replacement procedures 87

Operator display

The operator display is located on the front door of the MCS unit.

The following tools are required for installation:

• 8-mm socket

• Small Flathead screwdriver

Removing the operator display

1. Power down the MCS unit ("Powering down the MCS unit" on page 24).

2. Open the front MCS door.

3. Using an 8 mm socket or wrench, remove the three nuts and external star washers securing the

operator display rear cover to the back of the front MCS door.

4. Remove the operator display rear cover.

Removal and replacement procedures 88

5. Disconnect the connector between the operator display and the display button.

6. Disconnect the connector from the management module (1), and pull the cable up through the cable

management hose (2).

7. Squeeze the four release tabs on the top and bottom of the operator display (1), and push the

operator display from the back to the front through the front MCS door (2).

NOTE: Cables are removed for clarity.

Removal and replacement procedures 89

8. Remove the display button by squeezing the two release tabs on the sides of the display button (1)

and pushing the display button from the back to the front through the front MCS door (2).

To replace this component, see "Replacing the operator display (on page 91)."

Removal and replacement procedures 90

Replacing the operator display

1. Hold the four release tabs while pushing the operator display from the front to the back through the

front MCS door.

2. Hold the two release tabs while pushing the display button from the front to the back through the

front MCS door.

Removal and replacement procedures 91

3. Push the cable down through the cable management hose (1), and connect it to the management

module connector (2).

4. Connect the connector between the operator display and display button.

5. Slide any extra slack in the cable lines up into the operator display rear cover, and secure by

inserting the rubber grommet into the designated notch on the operator display rear cover.

Removal and replacement procedures 92

6. Using an 8 mm socket or wrench, secure the operator display rear cover to the back of the operator

display by inserting three nuts and external star washers.

7. Complete the operation checklist (on page 111).

Power inlet box

The power inlet box is not a spare part. The relocation instructions for the power inlet box are provided so
that you can access other components.

Relocating the power inlet box

No tools are required for this procedure.

1. Disconnect the green and yellow ground bonding wire grounding the outer support bracket to the

MCS unit.

2. Remove the outer support bracket.

a. Loosen the four thumbscrews securing the outer support bracket to the MCS unit (1).

Removal and replacement procedures 93

b. Lift the right side of the bracket up at a slant, and pull the bracket out of the MCS unit (2).

IMPORTANT: Do not disconnect any of the internal electrical connections to the power inlet

box.

3. Pull the power inlet box toward you until it stops.

Removal and replacement procedures 94

4. Set the power inlet box aside in the side cavity by lifting the right side of the power inlet box up until

the box sits vertically on the left side of the MCS unit.

To replace this component, see "Relocating the power inlet box back into position (on page 95)."

Relocating the power inlet box back into position

1. Lower the right side of the power inlet box until it is back into the horizontal position.

Removal and replacement procedures 95

2. Push the power inlet box back into the MCS unit until it locks in place.

3. Replace the outer support bracket.

a. Lift the right side of the bracket up at a slant, and slide the bracket into the MCS unit.

b. Tighten the four thumbscrews to secure the outer bracket to the MCS unit.

4. Connect the green and yellow ground bonding wire to ground the outer support bracket to the MCS

unit.

Removal and replacement procedures 96

Water group controller

The water group controller is located at the bottom front of the MCS unit.

The following tools are required for installation:

• T-25 Torx driver

• Flathead screwdriver

• 8-mm socket

Removing the water group controller

1. Power down the MCS unit ("Powering down the MCS unit" on page 24).

2. Remove the AC transfer switch ("Removing the AC transfer switch" on page 26).

3. Disconnect the seven electrical cables in the front of the water group controller.

Removal and replacement procedures 97

4. Using an 8 mm socket, remove the two 8 mm nuts and washers securing the water group controller

bracket to the water group controller chassis.

5. Disconnect the two large electrical cables from the back of the water group controller.

6. Disconnect the green and yellow grounding wire securing the water group controller to the water

group controller chassis.

Removal and replacement procedures 98

7. Remove the water group controller (mounted on a bracket) from the water group controller chassis.

8. Slide the water group controller off of the mounting bracket.

To replace this component, see "Replacing the water group controller (on page 100)."

Removal and replacement procedures 99

Replacing the water group controller

1. Slide the water group controller onto the mounting bracket until it locks in place.

2. Connect the green and yellow grounding wire to secure the water group controller to the water

group controller chassis.

3. Connect the two large electrical cables to the back of the water group controller.

Removal and replacement procedures 100